Method and apparatus for packaging and dispensing goods

ABSTRACT

An packaging apparatus is disclosed that comprises, a tray having a top surface, a bottom surface, and a sidewall, one or more compartments integrally formed with and extending from the tray, and one or more pods for housing a product, the pods further comprising, a pouch with a cover secured to the pouch to provide closure of the pod, the cover including a bottom cover surface and a top cover surface, and a tab layer secured at least partially to the top cover surface, wherein the pods are received and at least partially enclosed by the compartments, and the pods are secured to the tray.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present Application is a non-provisional application and claims the benefit of U.S. provisional patent application No. 61/757,842 having the same title as the present Application and filed on Jan. 29, 2013, of which the present Application hereby incorporates by reference in its entirety.

FIELD

The method and apparatus relate to the packaging and dispensing of goods.

BACKGROUND

Products can be packaged together in numerous ways to provide advantages with storage, transport, dispensing, and cost. Commonly, products such as food can be combined in large quantities in a container to save on the cost of extra packaging materials. Alternatively, a small quantity of products can be packaged together to maintain separation and/or freshness. For example, coffee creamer can be purchased in a large 1-liter bottle or in a box of 192 individually packaged 13-milliliter units. Although these individual units provide a solution for maintaining freshness, they require extensive packaging materials and are positioned loosely about the box, making accounting difficult as the units are consumed, and creating organizational storage problems if they are removed from the box.

BRIEF SUMMARY

In at least some embodiments, the method and apparatus relate to a packaging tray apparatus that includes a substantially planar substrate having a top surface, a bottom surface, a sidewall, and one or more compartments integrally formed with and extending from the substrate.

Further, in at least some embodiments, the method and apparatus relate to a pod apparatus that includes a pouch for housing a product, a cover secured to the pouch to provide closure, and a tab layer secured at least partially to the cover to provide a graspable portion.

Additionally, in at least some embodiments, the method and apparatus relate to an apparatus that includes a substrate material having a top surface, a bottom surface, and a sidewall; one or more compartments integrally formed with and extending from the substrate; one or more pods for housing a product, the pods further comprising a pouch, a cover secured to the pouch to provide closure, the cover including a bottom cover surface and a top cover surface, and a tab layer secured at least partially to the top cover surface, wherein the pods are received and at least partially enclosed by the compartments, and the pods are secured to the substrate.

In addition, in at least some embodiments, the method and apparatus relate to a method of packaging goods that includes filling a pouch with a product; securing the pouch to a cover to enclose the product, wherein the cover includes a tab layer secured thereto; providing a substrate material having a top surface and one or more compartments extending therefrom; positioning the pouch inside a compartment of a tray, wherein the tray includes a top surface; and securing the cover to the tray top surface.

Other embodiments, aspects, features, objectives, and advantages of the method and apparatus will be understood and appreciated upon a full reading of the detailed description and the claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the method and apparatus are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The method and apparatus are not limited in their application to the details of construction or the arrangement of the components illustrated in the drawings. The method and apparatus are capable of other embodiments or of being practiced or carried out in other various ways. In the drawings:

FIG. 1 is a top view of an exemplary packaging and dispensing apparatus that includes a packaging tray and a pod;

FIG. 2 is a side view of the packaging and dispensing apparatus of FIG. 1;

FIG. 3 is a cross-sectional view of an exemplary pod; and

FIG. 4 is an enlarged cross-sectional view of the pod of FIG. 2 and a portion of the packing tray of FIG. 2.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, an exemplary packaging and dispensing apparatus 100 is illustrated. The packaging and dispensing apparatus 100 includes an exemplary packaging tray 102 that is configured to secure and dispense one or more pods 104 that individually contain one or more products 106. The packaging and dispensing apparatus 100 provides a convenient and efficient method of packaging products 106 that provides for bulk shipping and storage, while allowing for individual dispersion of pre-determined amounts of product 106.

The exemplary packaging tray 102 and pods 104 can include numerous embodiments. Referring particularly to FIG. 1, the tray 102 includes a substrate 108 having a tray top surface 110, a tray bottom surface 112, and a tray sidewall 114. The substrate 108 can, in at least some embodiments, be comprised of numerous materials, such as paper, laminates, plastic, metal, and any combination thereof (e.g., plastic film coated with a metalized layer). Further, in at least some embodiments, the substrate 108 can be substantially planar and include a semi-rigid tray sidewall 114 having a thickness of about 3 mm to about 10 mm, and an oxygen transmission rate (OTR) in the range of about 0.00 cc/100 sq. in. to about 0.05 cc/100 sq. in. In addition, the substrate 108 can have a length L of about 10 cm to about 150 cm and a width W1 of about 5 cm to about 50 cm. In other embodiments, the substrate 108 can have various other thicknesses, lengths, widths, rigidity levels, and gas permeability levels. The tray 102 can further include a product label 130 (e.g., indicia) for identification of the product 106, UPC code, etc. In addition, the tray 102 can include an aperture 132 for providing a hanging position on a rack. Further, the substrate 108 can include scoring between the openings 116 to allow for separation of the pods 104 while intact in the tray 102.

One or more openings 116 are provided in the substrate 108, with each opening 116 including a rim portion 118 located on the substrate 108 that extends adjacent to and around the opening 116. One or more compartments 120 are integrally formed with the substrate 108 at the openings 116 and extend downward from the substrate 108. The compartment 120 is configured to receive the pods 104 and provide a sealable, protective, recessed storage position. The quantity of compartments 120 formed in the tray 102 can vary. In at least some embodiments from 1 to about 12 compartments can be provided, while in other embodiments 1 to about 48 compartments can be provided, while in still other embodiments, more than 48 compartments can be provided. The compartments 120 include a compartment sidewall 122 that extends from the tray bottom surface 112 to a compartment bottom surface 124. The compartments 120 can include various shapes and sizes to accommodate various types of products 106, for example, cylindrical, conical, rectangular, convex, etc. Further, in at least some embodiments, the substrate 108 includes a plurality of perforations 126 to facilitate separation of the substrate for removal of individual pods 104 from the tray 102.

In at least some embodiments, as shown in FIG. 2, the compartments 120 include a tapered-cylindrical shape, and extend a height H (vertical distance between the tray bottom surface 112 and the compartment bottom surface 124) of about 30 mm to about 40 mm. Further, the width W2 of the opening 116 can extend from about 40 mm to 46 mm, and the width W3 of the compartment bottom surface 124 can extend from about 35 mm to about 41 mm. In another embodiment, the height H extends from about 5 mm to about 100 mm and the widths W2 and W3 extend from about 5 mm to about 25 cm. In other embodiments, the height H and widths W2 and W3 include greater or lesser distances. In at least some embodiments, the substrate 108 can include one or more access depressions 134 (FIGS. 1 and 2).

Referring to FIG. 3, an exemplary pod 104 is illustrated. The pod 104 can be utilized to store one or more of various products 106, such as consumables (i.e., food products), medical supplies, chemicals, cosmetics, etc. The pod 104 includes a pouch 140 having an upper portion 142, a lower portion 144, an inner surface 146, and an outer surface 148. The pouch 140 can include one or more of various materials suitable for housing products 106. The pouch 140 can vary in shape, size, and composition dependent on the type of product 106 to be housed in the pouch 140. In at least some embodiments, the pouch 140 can include one or more of various materials suitable for filtering, for example, non-woven paper, woven fiber meshing, and synthetic meshing. In other embodiments, the pouch 140 can be comprised of a waterproof material, such as plastic, to accommodate liquid products 106.

The pod 104 further includes a cover 150 that is secured to the pouch 140 to secure the product 106 inside the pod 104. The cover 150 includes a cover bottom surface 154 and a cover top surface 156. When the cover 150 is secured to the pouch 140, the cover bottom surface 154 and the inner surface 146 of the pouch 140 form a product chamber 172 for housing the product 106. The pouch upper portion 142 is secured to the cover bottom surface 154. Securement of the pouch 140 to the cover 150 can be accomplished in various manners, such as through the use of an adhesive 152 (e.g., heat sealable paper, etc.). If the product 106 is a consumable, then food grade adhesive can be used. In at least some embodiments, the adhesive 152 can include or serve as a sealant 160. The cover 150 can be comprised of one or more of various materials, such as paper, plastic, foam, plastic film, silicon rubber, metal foil on paper, coated paper (wax, starch, or other coating layer that prevents oxygen and/or water transfer), etc. In at least some embodiments, the cover 150 has a thickness T ranging from about 1 mm to about 10 mm, although in other embodiments, the thickness T can be less than 1 mm or greater than 10 mm. Further, in at least some embodiments, the cover 150 is comprised of a material with a low gas permeability, for example an OTR of less than 1.0, although in other embodiments the OTR can be greater than or equal to 1.0.

In addition to sealing the pouch 140, the cover 150 also provides for securement of the pod 104 to the tray top surface 110, and thereby securing the pouch 140 inside the compartment 120. Referring to FIG. 4, the pod 104 is illustrated in a securement position with the tray 102. More particularly, the cover bottom surface 154 is secured to the rim portion 118 of the substrate 108. In at least some embodiments, this is accomplished using a sealant 160 that adheres and seals the cover bottom surface 154 to the rim portion 118. The sealant 160 can include, for example, heat sealable laminate that can be peeled off, non-permanent adhesive tape, non-permanent glue, and pre-formed sealant rings. The cover 150 is sized and shaped to overlap the opening 116 and includes a sealing portion 162 that is positionable over the rim portion 118 of the substrate 108. The cover 150 has a diameter D (FIG. 1) that is sized and shaped to cover the opening 116 and extend over the rim portion 118. In at least some embodiments, the diameter D is about 5 mm to about 150 mm, although in other embodiments, the diameter D can be less than 5 mm and greater than 150 mm. In addition, the opening 116 and/or the cover 150 can be the same shape or different shapes, including circular, square, etc. In at least some embodiments, the substrate 108 includes perimeter depressions 164 that allow for a flush or at least partially flush mounting of the cover 150 relative to the tray top surface 110, as shown in FIG. 4. In other embodiments, the substrate is flat or substantially flat, as shown in FIG. 2.

In at least some embodiments, a tab layer 166 can be provided integral with, or secured at least partially to, the cover top surface 156. The tab layer 166 includes a tab portion 168 that can be accessed and pulled to break the seal formed by the sealant 160 and remove the pod 104 from the tray 102. The tab layer 166 can be comprised of one or more of various materials and can be sized greater than, equal to, or smaller than the cover top surface 156. The tab portion 168 is formed with the tab layer 166 and can be temporarily secured to the cover top surface 156 with an adhesive 157 and forcibly released from the cover top surface 156 for accessibility. The adhesive 157 can be a light-tack adhesive to allow for easy lifting of tab portion 168 from the cover top surface 156. The tab portion 168 can also be an extended portion of the tab layer 166 that extends beyond the cover top surface 156 for convenient accessibility. The tab layer 166 can be comprised of one or more of various materials, such as paper, plastic film, metal foil, etc. In at least some embodiments, the tab portion 168 can also be used to remove the cover 150 from the pouch 140, when the product 106 is not intended to remain in the pouch 140 during use. Alternatively, the tab portion 168 can be used to remove the pod 104 from the tray 102 and the cover 150 can be secured to the pouch 140 with adhesive 152 that allows for practical removal of the cover 150. In addition, in at least some embodiments, pulling on the tab portion 168 provides removal of the pod 104 from the tray 102 without removing the cover 150 from the pod 104, thereby leaving the product 106 sealed inside the pod 104 after removal from the tray 102.

In at least some embodiments, the product 106 includes ingredients for brewing coffee (i.e., processed coffee beans, flavorings, etc.). When the pod 104 is intended for brewing coffee, the pod 104 can be sized and shaped to be placed inside a coffee brewer machine, such as coffee brewer machines manufactured by Keurig Inc. (e.g., Keurig K-Cup compatible brewers). In such an application, the cover 150 and tab layer 166 are configured to be penetrable by a puncturing needle of a coffee brewer machine. In contrast to various K-Cup style products used by various coffee brewer machines, the pods 104 can be manufactured with a filter pouch 140 instead of a plastic housing, wherein the filter pouch 140 is adhered to the cover 150 without the need for reinforcement or the inclusion of plastic. As such, the pod 104 can be manufactured using only paper-based materials, eliminating the need for the use of plastic. The elimination of plastic allows for the pod 104 to be biodegradable, and eliminates the need for recycling. Likewise, the tray 102 can be manufactured using only paper-based materials and also be biodegradable. Further, by securing the pods 104 directly to the tray top surface 110, the need for an overlay or covering (plastic laminate, etc.) on the tray top surface 110 is eliminated. In addition, the individual sealing and adhering allows for a variety of pods 104 to be installed in the compartments, with each compartment 120 having a suitable gas to accommodate the product 106 therein. For example, coffee flavorings can require nitrogen, while apple cider ingredients can require a different gas injection. In addition, during manufacturing, the compartments 120 need not be filled in each tray 102 prior to sealing the pods 104 to the tray 102, thereby providing flexibility for at least the addition of pods 104 with different products 106, such as a multi-pack. Further, as the cover 150 can be semi-rigid or rigid, the pod 104 is suitable for use in various coffee brewer machines that require a substantially rigid top surface to accommodate a puncturing needle. In contrast, a pod 104 having a soft filter-based portion on top would not function in such coffee brewers, instead requiring insertion into a beverage cup for the addition of hot water.

As brewer machines often include the capability of brewing beverages other than coffee, such as tea, cocoa, cider, etc., the pouch 140 can include, as the product 106, the necessary ingredients for other beverages (e.g., tea leaves, dehydrated apple cider, etc.). In addition, by packaging the pod 104 within the tray 102, the pod 104 requires less material to support or protect the product 106, thereby reducing both the cost of each pod 104 and the effect on the environment. Additionally, as the size of the pouches 140 and compartments 120 can vary, the amount of product 106 can be varied to provide a greater or lesser quantity of product 106 in each pod 104. Further, the quantity of product 106 can be varied in each pod 104 without changing the overall dimensions. For example, in at least some embodiments, if the product 106 includes coffee grinds, the amount of product 106 can range from about 10 grams to about 60 grams, to provide a consumer with a greater range of choices for strength of the coffee brewed from the pod 104.

To provide and/or maintain a suitable environment for various types of products 106, the compartment 120 can be injected with a gas 170 (FIG. 4), such as nitrogen, that displaces the oxygen to reduce oxidation or other sources of degradation of the product 106 over time. The gas 170 is sealed in the compartment 120 by the cover 150, which is sealed to the tray top surface 110 with the sealant 160. This seal is maintained until a consumer lifts the pod 104 out of the tray 102 by pulling the tab portion 168 and detaching portions of the sealant 160. As the packaging and dispensing apparatus 100 provides a sealed product 106, no additional overwrap or display enclosure is required. The packaging and dispensing apparatus 100 can include all necessary and/or desired graphics, such as displayed on the tray top surface 110 and/or tab layer 166. The packaging and dispensing apparatus 100 can be configured to include depressions or protrusions that enhance stackability, both when the pods 104 are in the tray 102 and after the pods 104 have been removed.

In addition to food-based products, various non-consumables, such as medical supplies, medicines, etc., can be stored in the pods 104. Use of the pods 104 in combination with the tray 102 allow for products 106 to be contained in a sterile environment until needed, while allowing them to be manufactured, shipped, and/or stored in an efficient manner. For example, if the product 106 was a medical instrument, such as a scalpel or clamp, the packaging and dispensing apparatus 100 can be placed in a surgical suite to provide a surgeon access to a selection of medical instruments, without the need to expose unused medical instruments to the environment. Likewise, a portioned amount of a disinfectant, such as iodine and alcohol, can be located in the pods 104 for use by surgical staff, emergency medical technicians (EMT), emergency room staff, school nurses, etc. Use of the tab portion 168 can assist with maintaining sterilization by reducing a user's possible contact with the pouch 140. Additionally, by providing pre-measured amounts of a chemical (e.g., medicine, disinfectant, etc.), the need for measuring devices can be omitted, thereby reducing waste of the chemical as well as contamination of the measuring device. The pod 104 can also include other products 106, such as adhesives, sealants, and lubrication (e.g., grease, glue, oil), thereby providing a storage and delivery system with a reduced need for a user to contact such products 106.

When the product 106 is a food-based product, the use of the pods 104 allow for pre-portioned servings and can be utilized to limit exposure of the product 106 to sources of contamination (bacteria, virus, etc.). For example, assuming an egg shell has been sterilized, the egg content can be removed from the shell, then placed in the pods 104, thereby preventing exposure of the egg content to later introduced contaminants when a user cracks open the egg for consumption. In at least some embodiments, the cover 150 can include a bubble-shaped reservoir to hold and dispense liquid. In another embodiment, the cover 150 can include a mechanism that when the cover 150 is depressed, a secondary liquid or powder can be released into a primary liquid and then extracted to a bubble-shaped reservoir, wherein the mixing occurs in a sterile oxygen-free environment without direct contact by a user.

An exemplary method of manufacturing the packaging and dispensing apparatus 100 includes inserting a product 106 inside the pouch 140, securing the cover 150 to the upper portion of the pouch 142 using the adhesive 152 to form the pod 104, wherein the cover 150 includes a tab layer 166 secured thereto; inserting the pod 104 into the compartment 120 of the tray 102, injecting a gas 170 inside the compartment 120 to displace oxygen, and sealing the tray bottom surface 112 to the rim portion 118 of the tray top surface 110.

It should be appreciated that the present disclosure is intended to encompass numerous embodiments as disclosed herein and further described by the following:

-   -   (i). A pod apparatus comprising:         -   a pouch for housing a product;         -   a cover secured to the pouch to provide closure; and         -   a tab layer secured at least partially to the cover to             provide a graspable portion.     -   (ii). The apparatus of (i), wherein the cover is formed of a         rigid material and the tab layer is formed of a flexible         material.     -   (iii). The apparatus of any one of (i-ii), wherein only a         portion of the tab layer is removable from the cover.     -   (iv) An apparatus comprising:         -   a tray having a top surface, a bottom surface, and a             sidewall;         -   one or more compartments integrally formed with and             extending from the bottom surface of the tray;         -   one or more pods for housing a product, the pods further             comprising:             -   a pouch;             -   a cover secured to the pouch to provide closure of the                 pod, the cover including a bottom cover surface and a                 top cover surface; and             -   a tab layer secured at least partially to the top cover                 surface,         -   wherein the pods are received and at least partially             enclosed by the compartments, and the pods are secured to             the tray.     -   (v). The apparatus of (iv), wherein the cover bottom surface is         secured to the top surface of the tray.     -   (vi). The apparatus of any one of (iv-v), wherein the tab layer         includes a tab portion.     -   (vii). The apparatus of any one of (iv-vi), wherein the one or         more pods are separable from the tray by exerting a pulling         force on the tab portion.     -   (viii). The apparatus of any one of (iv-vii), wherein separation         of the one or pods using the tab portion does not separate the         cover from the pouch.     -   (ix). A method of packaging goods comprising:         -   filling a pouch with a product;         -   securing the pouch to a cover to enclose the product,             wherein the cover includes a tab layer secured thereto;         -   providing a substrate material having a top surface and one             or more compartments extending therefrom;         -   positioning the pouch inside a compartment of a tray,             wherein the tray includes a top surface; and         -   securing the cover to the tray top surface.     -   (x). The method of (ix), further comprising injecting a gas         inside the compartment to substantially displace oxygen in the         compartment.         It is specifically intended that the packaging and dispensing         apparatus 100 is not limited to the embodiments and         illustrations contained herein, but include modified forms of         those embodiments including portions of the embodiments and         combinations of elements of different embodiments as come within         the scope of the following claims. 

What is claimed is:
 1. A pod apparatus comprising: a pouch for housing a product; a cover secured to the pouch to provide closure; and a tab layer secured at least partially to the cover to provide a graspable portion.
 2. The apparatus of claim 1, wherein the cover is formed of a rigid material and the tab layer is formed of a flexible material.
 3. The apparatus of claim 1, wherein only a portion of the tab layer is removable from the cover.
 4. An apparatus comprising: a tray having a top surface, a bottom surface, and a sidewall; one or more compartments integrally formed with and extending from the bottom surface of the tray; one or more pods for housing a product, the pods further comprising: a pouch; a cover secured to the pouch to provide closure of the pod, the cover including a bottom cover surface and a top cover surface; and a tab layer secured at least partially to the top cover surface, wherein the pods are received and at least partially enclosed by the compartments, and the pods are secured to the tray.
 5. The apparatus of claim 4, wherein the cover bottom surface is secured to the top surface of the tray.
 6. The apparatus of claim 4, wherein the tab layer includes a tab portion.
 7. The apparatus of claim 6, wherein the one or more pods are separable from the tray by exerting a pulling force on the tab portion.
 8. The apparatus of claim 7, wherein separation of the one or pods using the tab portion does not separate the cover from the pouch.
 9. A method of packaging goods comprising: filling a pouch with a product; securing the pouch to a cover to enclose the product, wherein the cover includes a tab layer secured thereto; providing a substrate material having a top surface and one or more compartments extending therefrom; positioning the pouch inside a compartment of a tray, wherein the tray includes a top surface; and securing the cover to the tray top surface.
 10. The method of claim 9, further comprising injecting a gas inside the compartment to substantially displace oxygen in the compartment. 